Engineer Training

Motion Control

TJ8300 / TJ8500

Motion Control

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Motion Control

TJ8300 / TJ8500Components

Motion control system includes the following components:

GALIL DMC (Ethernet Motion Controller Driver)

Drum motion system – Drum driver unit, Drum motor,and encoder

MCDU – Motion control / drivers unitResponsible for the motion system of the following: Bridge Loader Buffer Bridge stepper Registration (optional)

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Motion Control

TJ8300 / TJ8500DMC Galil Board

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Motion Control

TJ8300 / TJ8500DMC Galil Board (Cont.)

This board controls four motion axes:

Drum motor – X-axis

Loader motor – W-axis

Buffer motor – Z-axis

Bridge motor – Y-axis

1. Positioned in the control unit and communicates with the computer network via Ethernet cable.

2. Controls the motors by sending control voltages and inhibiting signals to the motor drivers.

3. Encoders monitor the drum, loader, buffer and bridge movement.

4. The encoder signals are sent back to the GALIL board in order to close the motion loop.

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Motion Control

TJ8300 / TJ8500Drum Driver Unit

Located in the electronic cabinet.

Input operation voltage of 75VAC.

There are 3 LED indicators in the front of the Drum motor driver: Power – Green LED – indicates power input (75VAC) Motor out – Green-yellow LEDs – indicates the motor

polarity:• Green light – the drum rotates in one direction.• Yellow light – the drum rotates in the opposite direction.• Light is off – The motor is IDLE.

Driver status – Green-red LEDs – indicates the driver status:• Green light – the drum is jogging or in stop mode.• Red light – the drum is idle or there is a driver fault like

Overheat /Over voltage.

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Motion Control

TJ8300 / TJ8500Drum Motion System

Drum driver

DrumMotor

Diode bridge

Output filter

Capacitor

75VAC

Encoder

GALILBoard

Inhibitsand Controlsignals

Encoder A+ ,A- ,B+ ,B- and Home signals

Shunt regulator

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Motion Control

TJ8300 / TJ8500Drum Driver Unit

The drum driver works similar to the PRESS jet II, but with two additional units:

Shunt regulator – over voltage protection for the drum driver, including the fuse for protection inside the drum driver

Output filter – essential, due to the long cable between the drum driver and the drum motor

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Motion Control

TJ8300 / TJ8500Drum Driver Unit (Cont.)

Front view

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Motion Control

TJ8300 / TJ8500Drum Driver Unit (Cont.)

Back view

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Motion Control

TJ8300 / TJ8500Drum Motion System

Tension pulley

Motor pulley

Encoder systemDrum pulley

Drum motor

Micro-V belt

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Motion Control

TJ8300 / TJ8500Drum Motion System (Cont.)

The drum motion system components include:

Drum motor

Motor pulley

Drum pulley

Drum encoder

Micro-V belt

Tension pulley

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Motion Control

TJ8300 / TJ8500Drum Motion System (Cont.)

1. The drum motor rolls the drum pulley.

2. The micro-V belt, which is stretched by the tension pulley, transfers the movement to the drum pulley.

3. The micro-V belt is a safe and reliable belt, designed to prevent the belt from sliding off.

4. An extra belt is rolled on the inner side of the drum pulley.

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Motion Control

TJ8300 / TJ8500Drum Motor

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Motion Control

TJ8300 / TJ8500Drum Motor (Cont.)

This motor rotates the drum.

This motor is controlled by the GALIL DMC Board.

It is placed under the power printing bracket.

In order to have clear and easy access to the motor, the electronic cabinet can be moved away (up to 1 meter) from the printing unit.

The drum motor has a built in taco-generator for over-speed/under-speed indications.

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Motion Control

TJ8300 / TJ8500Drum Encoder System

Reading head

Encoder scale

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Motion Control

TJ8300 / TJ8500Drum Encoder System (Cont.)

This device is designed to track the drum motion.

A metal ring with a gold encoder scale is attached to the drum.

The encoder scale is divided into reading units, translated to a resolution of ~125,000 pulses/turn.

The encoder optic read head can be adjusted by several adjusting screws.

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Motion Control

TJ8300 / TJ8500Drum Encoder

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Motion Control

TJ8300 / TJ8500Drum Encoder (Cont.)

The drum encoder is placed on the drum itself, near the electronic cabinet side.

The drum encoder consists of three elements:

Strip tracker (RGR)

Optical head

Magnetic detector for drum home interrupt

The encoder read head counts pulses when the drum is rotating.

The home tracker tracks a small metal plate on the drum encoder ring in order to reset the home position.

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Motion Control

TJ8300 / TJ8500MCDU – Motion Control Drivers Unit

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Motion Control

TJ8300 / TJ8500MCDU – Motion Control Drivers Unit (Cont.)

4 Phases

Fuse for the Cutter

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Motion Control

TJ8300 / TJ8500MCDU – Motion Control Drivers Unit (Cont.)

STC Board

MCDB Board

Inside the unit:

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Motion Control

TJ8300 / TJ8500MCDU – Motion Control Drivers Unit (Cont.)

MCDU includes the following modules:

STC – stepper motors controller

Registration motor controller – optional (not in use)

MCDB (Motion Control Driver Board) controls the following: Bridge motion Loader (roller) motion Buffer motion Cutter motor Motion safety The MCDB also isolates and amplifies each one of the four

channels of the motion axis.

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Motion Control

TJ8300 / TJ8500MCDU – Motion Control Drivers Unit (Cont.)

The following Input powers are supplied from the supply unit to the MCDU:

24VAC – converted to 24VDC inside MCDU

12VDC – for stepper controller (STC)

5VDC – for MCDB and STC (optional)

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Motion Control

TJ8300 / TJ8500MCDU – Motion Control Drivers Unit (Cont.)

BridgeMotor

BufferMotor

RollerMotor

CutterMotor

Motionsafety

StepperMotors

OptionalRegistration

Motor

MCDB

Diode bridge

24VAC 24VDC

STC

5VDC

12VDC

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Motion Control

TJ8300 / TJ8500MCDU – Motion Control Drivers Unit (Cont.)

Connections at the back of the MCDU:

J1 – 24VAC, 12VDC and 5VDC input powers from thesupply unit

J2 – power output for all motors

J3 – controls from control bracket

J4 – control for drum driver

J5 – motion safety

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Motion Control

TJ8300 / TJ8500MCDU – Motion Control Drivers Unit (Cont.)

Motion safety:

Cover switches

Under speed protection

Over speed protection

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Motion Control

TJ8300 / TJ8500MCDU – Motion Control Drivers Unit (Cont.)

Cover switches:

If a cover is opened, the following sequence begins:

1. All motors are stopped from the RT software.

2. After a four second timeout, the GALIL software (GALIL limit switch) stops all motors.

3. After a timeout of another four seconds, the hardware carries out a full stop of the motors by disabling the motion drivers.

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Motion Control

TJ8300 / TJ8500MCDU – Motion Control Drivers Unit (Cont.)

Under speed protection

The main purpose is to protect the drum from overheating.

There are two separate systems for under speed protection:

Tacho generator – generates voltage, proportional to the drum motor speed.

• If the voltage is less than the preset value in the Motion Control Drivers board inside the MCDU, under speed protection is enabled and automatically shuts down the power to the IR units to protect the drum.

Under speed sensor – monitors the drum movement.

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Motion Control

TJ8300 / TJ8500MCDU – Motion Control Drivers Unit (Cont.)

Complete shut down of IR and Hot air units

Tacho generator

Under speed sensor

Printer signal bracket

Electricalcabinet

Control unit

MCDU Controlunit

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Motion Control

TJ8300 / TJ8500MCDU – Motion Control Drivers Unit (Cont.)

Over speed protection

Tacho generator generates voltage, proportional to the drum speed. If the voltage exceeds the preset value in the Motion Control Drivers Board inside the MCDU, over speed protection is enabled and automatically shuts down the 75VAC power to the drum driver (provided inside the supply unit).

There is an over speed push button in the front of the MCDU, which must be reset in case of over speed.

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Motion Control

TJ8300 / TJ8500MCDU – Motion Control Drivers Unit (Cont.)

Tacho generatorPrinter signal

bracket

Supplyunit

MCDU

Complete shut down of 75VAC for drum driver

Controlunit

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Motion Control

TJ8300 / TJ8500MCDU – Motion Control Drivers Unit (Cont.)

Indications and fuses:

Over speed release push button

24VDC indication light for motion driver board

24VDC indication light for cutter motor and registration motor (not in use). The light indication is connected after the fuse protection.

Light indication for cover switches

Light indication for over speed

Light indication for under speed (Tacho)

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Motion Control

TJ8300 / TJ8500MCDU – Motion Control Drivers Unit (Cont.)

Light indication for under speed (proximity)

Four light indications for stepper motor, one for each phase

Four light indications of output voltage for the following motors:

Bridge

Buffer

Loader

Cutter motors

Lights for these motors change from green to yellow according to the voltage polarity (indicates the motor movement direction).

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Motion Control

TJ8300 / TJ8500MCDU – Motion Control Drivers Unit (Cont.)

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Motion Control

TJ8300 / TJ8500Bridge Steppers Motion

STC controller, which is located inside the MCDU controls the two stepper motors on the bridge.

Via the computer, the operator can control the bridge backwards/forwards movement relative to the drum.

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Motion Control

TJ8300 / TJ8500Bridge Stepper Motors

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Motion Control

TJ8300 / TJ8500Bridge Stepper Motors (Cont.)

There are two stepper motors on the bridge.

These motors enable the bridge Z-axis motion towards and away from the drum.

Each motor on each side of the bridge is a stand-alone unit.

Each motor receives the same control signal from the STC board, which is located inside the MCDU.

The two motors are not connected in their motion.

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Motion Control

TJ8300 / TJ8500Bridge Limit Sensors

There are four sensors on the bridge Z axis:

Two forward – proximity sensors

Two backwards – mechanical sensors

The two forward sensors are in plot position and the two backward ones are in maintenance position.

These sensors are connected to the STC board, enabling it to detect the motion limits of the bridge stepper motors.

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Motion Control

TJ8300 / TJ8500Bridge Backward/Forward Switches

Backward limit switch Forward proximity sensor

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Motion Control

TJ8300 / TJ8500Bridge Motor and Encoder

Print motorLinear encoder Motor encoder

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Motion Control

TJ8300 / TJ8500Bridge Motor and Encoder (Cont.)

This motor enables the motion of the bridge printing axis.

It is controlled by the GALIL DMC Board.

A linear encoder controls its operation.

The linear encoder has a built in index (bridge home).

The encoder signal is sent to the GALIL to indicate the motor speed and location.

The bridge motor and encoder are placed on the edge of the right bridge roll in the chassis.

The motor has a belt, transferring its rotation to the bridge roll.

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Motion Control

TJ8300 / TJ8500Roller Motor and Encoder Connections

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Motion Control

TJ8300 / TJ8500Roller Motor and Encoder

Roller motor&

encoderBehind the chassis wall

Pulley andTiming belt

Loaderroll

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Motion Control

TJ8300 / TJ8500Roller Motor and Encoder (Cont.)

1. This motor enables the pulling of the substrate towards the buffer in the loading system.

2. It is controlled by the GALIL DMC Board.

3. A built-in encoder controls the motor operation.

4. Controlling the roller motor movement enables the defining of the media length, which will be inserted towards the buffer.

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Motion Control

TJ8300 / TJ8500Roller Motor and Encoder (Cont.)

5. The encoder signal is sent to the GALIL to indicate the motor speed and monitor the movement.

6. The roller motor and encoder are placed in the loading system above the buffer.

7. It has a belt, which transfers its rotation to the loader roll.

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Motion Control

TJ8300 / TJ8500Buffer Motor and Encoder

Buffer motor encoder

Buffer belts

Timing belt

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Motion Control

TJ8300 / TJ8500Buffer Motor and Encoder (Cont.)

1. This motor rolls the buffer belts to enable the substrate to roll in and out from the buffer.

2. It is controlled by the GALIL DMC Board.

3. The buffer motor has a built in encoder in order to control the substrate length, which goes out from the buffer output tray towards the drum’s grippers.

4. The encoder signal is sent to the GALIL to indicate the motor speed and direction.

5. The buffer motor and encoder are placed above the buffer.

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Motion Control

TJ8300 / TJ8500Interface Boards

Buffer, motor,encoder interface board

Roller, motor, encoder interface board

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Motion Control

TJ8300 / TJ8500Interface Boards (Cont.)

Each encoder has its own interface board.

The interface board is connected to the encoder, and eventually to the GALIL DMC Board.

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Motion Control

TJ8300 / TJ8500MCDU - Cutter System

To Cutter Motor

Cutter flag right-to I/O (type I)

Cutter flag left-to I/O (type I)

Cut commandfrom I/O (type I) controller

Right Cutter Limit

Switch

Left Cutter Limit

Switch

MCDU

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Motion Control

TJ8300 / TJ8500MCDU - Cutter System (Cont.)

Cutter motor, pulley and belt

Cutter knife

Two magnetic proximity sensorsCutter disc 1

Cutter disc 2